Suzuki DR650 airbox modifications to help my ProCycle jet kit breathe better.

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Dino’s Tinker Shed, S2-Ep6. Suzuki DR650 Air box modifications
In this episode I will modify the air box door on my Suzuki DR650. I am doing this to add air flow to the engine after installing the ProCycle jet kit for the Suzuki DR650 which requires either cutting open the top of the air box or leaving off the air box door, neither of these two options appeals to me so I am going a different route.
I decided to make my own aluminum door frame and install Outerwears Pre-Filter cloth in the frame. This will keep out unwanted dust, mud and even water while still allowing air to move freely into the airbox and allow me to tune the bike as per ProCycles instructions.
I am not sure how well this mod will work but I will be making a follow up video in the spring dedicated to tuning the jet kit and I will review this mod at that time.
As always I have included time code chapters below so you can skip around to the information you are looking for if you do not want to view the entire vide.
Time Code Chapters:
00:00- Cold opening
01:16- Intro
01:36- Overview of the project
02:02- Cutting the rough shape
03:38- Cleaning up the surfaces
04:40- Drilling the mounting holes
05:42- Dry fit test
06:24- Looking at the “Outerwears” Pre filter cloth
07:30- Installation of Hook and Loop
08:15- Installation of filter cloth
09:47- Paint
10:15- Installation of the foam gasket
10:52- Fitting the door
Music:
I Found an Answer by Twin Musicom is licensed under a Creative Commons Attribution 4.0 licence. creativecommons.org/licenses/...
Artist: www.twinmusicom.org/

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Опубликовано:

20 июл 2024

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Комментарии : 61

@dwaynebanks5644 3 месяца назад

I like your channel very much. You could make instruction videos for a living! Good job!

@DinosTinkerShed 3 месяца назад

Thanks for the comment, I'm glad you like it. Dino

@volvogt21 2 года назад

Lovely work Dino. Thankyou for adding in the snow scene. Beautiful.

@DinosTinkerShed 2 года назад

My pleasure 😊 Dino

@HarleyDavidsonHeaven 5 месяцев назад

Another great video! Wow you are very handy and you come up with great solutions. I'm learning a lot by watching your channel, thank you.

@DinosTinkerShed 5 месяцев назад

I'm glad you are enjoying the content Dino

@loucee569 2 года назад

That was a great little project Dino!

@DinosTinkerShed 2 года назад

Thank you 🤗 Dino

@bradcrossman5068 2 года назад

Two feet of snow?? Some people have all the luck.😏 Good luck with the carb update. Previous owner of mine did the jet kit and hole-sawed the air box. Further mods were done with duct tape to reduce the number of holes. Runs great. A buddy has a pumper carb on his and swears mine is more responsive. YMMV. Cheers Lad!

@demetriuscooksey7147 Год назад

Pretty slick. Thanks for sharing

@BikerBytes 2 года назад

Great idea mate, saves drilling out the top of the air box where water could easily get in. Good stuff.

@DinosTinkerShed 2 года назад

Thanks, hopefully it works lol. I'll keep everyone updated when I tune the bike . Thanks for the comment, love your channel. Dino

@BikerBytes 2 года назад

@@DinosTinkerShed I'll look forward to the update. ATB Jason 👍

@paul1858 2 месяца назад

You ended up removing this right? Not judging just wondering if im getting the procycle jet kit timeline right in your videos haha.

@DinosTinkerShed 2 месяца назад

Yes I found the bike ran way too lean and was really loud. I'm sure with an aftermarket pipe and large jetting it would work, but for me, it was a bit more than air flow than I wanted to deal with. Thanks for the question. Dino

@royjmcc7 2 года назад

great vid Dino!

@DinosTinkerShed 2 года назад

thank you, glad you enjoyed it. Dino

@swissteam777 Год назад

Great video Dino, thanks for sharing. I may myself consider using a plastic recycle container to do the same, might be easy to work with.

@DinosTinkerShed Год назад

Thank you for the comment, I did find the bike ran a bit too lean with this mod, I do however still run the factory exhaust so that may be an issue. Please let me know how you make out. Dino

@swissteam777 Год назад

@@DinosTinkerShed If you run a free flow exhaust the lean problem will increase even more. I believe the best result for the stock exhaust is zero modification of the air box and simply remove the snorkel if you installed a jet kit.

@dropsofink1336 2 года назад

Great video

@DinosTinkerShed 2 года назад

Thanks Dino

@swexplorer 2 года назад

Fantastic mod. But did you start the bike and how did the bike react with all the new air it's getting? Very curious if you noticed any significant improvement.

@DinosTinkerShed 2 года назад

Not yet, I still have to tune it with the new jet kit, may be a while with all this snow. I will follow up on it though. Dino

@guillermoarias1898 Год назад

Quedó chingón 👌

@GoProDodge 2 года назад

Very cool stuff. I wonder how that stuff would work for my quad airbox. Following Bryan, I get filled up with fine dust.

@DinosTinkerShed 2 года назад

I have some extra

@GoProDodge 2 года назад

Summer project. 👍

@jarrodleis4046 2 года назад

I hope the air box and carb mods work out for you Dino but I would be prepared to put it back to stock. You will be getting a lot of additional intake noise that can be annoying at higher throttle settings. In the past I have attempted a similar process on my 1980 GS1100 but could not achieve satisfactory results. It seems that CV carbs are quite sensitive to vacuum to function properly. Anyway.. good luck and let us know how it works out in the spring. Hopefully you have a riding buddy with a good running stock DR you can compare to for a baseline. Now I have to break out my ZR8000 and take it out for it's maiden run this year. Heading to New Brunswick for a 6 day ride in 2 weeks.

@DinosTinkerShed 2 года назад

I am as interested as you are. the jet kit specified the additional air is required but I will have to see what the drone will be like with the cover opened up. My buddy Karl has the same kit in his and it ran much better than mine. I do not know about performance but it starts, idles and accelerated much smoother than mine. Just did close to 150km on the sled today, I'm tired, New Brunswick will be awesome, have fun! Dino

@bradcrossman5068 2 года назад

Heading to New Broomstick eh? The trails are great here now in the south.

@MalJ-eb7nv 2 года назад

I think that air box mod is better than drilling larger (permanent) holes in the top of the air box. If there is too much air you can easily reduce the open area if needed. Loved the opening pic - I used to travel to Toronto first week in March for a number of years and being from Aus loved the sight of the snow just outside the city area. Easy for me to say - I did not have to clear the driveway!! Gets bloody cold however.

@DinosTinkerShed 2 года назад

I agree, I can even make a new panel with a smaller whole, I tried to match the size of the cut out ProCycle provided in the kit, just use it on the cover instead of the top. I have always like the look of new snow as well, I think I look at the landscape in Australia the same way, it looks so amazing to me. I watch a lot of videos from the content creators over there, love it. Thank you again for the comment Mal. Dino

@justgjt 2 года назад

I could not imagine it... living in that snow and having it impact the daily routine. I guess it's just the reverse here in Australia as I don't go out on the bike when its 43 deg C (110 deg F) .. It's just unpleasant !

@ThomasReutter 2 года назад

Hey Dino....I have been enjoying your videos....thank you for your efforts. I just bought a stock 2020 DR650 and am doing the typical mods for performance and ergos...i am 6'3 and 295 lbs...I found 24 hyabusa pipe nearby and am waiting on a midpipe and a carb mod kit from procycle. Yours is the first i have seen of opening up the side of the airbox as opposed to the top...I really like the idea with the material you use to pre filter... Can you tell me what led you to do this as opposed to the top? Just curious.

@DinosTinkerShed 2 года назад

Really it is two things that pointed me on that direction. 1 I have read that some people who cut the top of the air box had issues with surging at certain rpm as the air box scavenged enough air to impact the small air filter under the seat which is connected to the CB carb. 2 my mod is fully reversible if I don't like it. Cutting the top of the air box is an all or nothing mod. Mine you can always reverse the entire job. I'm not yet sure how well it works as we have almost 4 feet of snow in my front yard right now. I will however do a video once the weather is favorable Thanks for the great question. Dino

@ThomasReutter 2 года назад

@@DinosTinkerShed Thanks for the quick reply. I should have my items in from procycle in a couple of weeks....I think i will try your mod...maybe Ill beat you to it to see how well it works as I am in Florida.

@benrecchi2880 Год назад

Hey Dino - I've seen as many videos as possible on DR650 mods and your videos are, by far, the most helpful and well edited! I've got the 150 jet, 4th needle space, and the top of the airbox opened up via the template. I've als got the Leo Vince slip on and I've ground down the header weld. The bike has always run lean, and has been getting worse. I'm getting amazing mileage, but still... I just wanted to ask about a follow up on the air box mod. How did it affect things? According to your previous install video, things seemed to be fine for you so what prompted you to open it up?

@DinosTinkerShed Год назад

Thank you for the comments and questions. I tried the air box mod to see what would happen, in the end though it was running way to lean so I put back on the stock air box. I think the idea is worth perusing if someone wanted to maximize the intake air flow potential but the jetting would need to be really rich and you would need a free flow exhaust. because I am using the stock exhaust the stock air box seems to work best still. I hope this helps. :) Dino

@benrecchi2880 Год назад

@@DinosTinkerShed Thanks for the reply! I was recently on the forums with the former owner or Procycle, and he mentioned that the airbox mod really only affects bog throttle openings and higher RPMs. I'm looking at the carb for my low throttle issues. I started with the float height but something looks off - the float tang is resting on the plunger itself without me pushing down on it at all. That seems wrong according to your other video. Any opinion on that?

@DinosTinkerShed Год назад

@@benrecchi2880 I may meet to review my own video, I can't quite envision what you are describing. Is the carb upside down when it is touching the tang?

@benrecchi2880 Год назад

Any thoughts on that? Seems weird to me

@DinosTinkerShed Год назад

@@benrecchi2880 Hi Ben, sorry for the slow rel=ply on this. Again I am not an expert when it comes to carb tuning, however if you have an aftermarket exhaust and opened up the air box the 150 carb may nor be enough to keep the air/fuel ratio rich enough. have you tried a ricer main jet?

@doublex632 2 года назад

Nice thanks, but have you ridden the DR since, that carb doesn't respond well to mods. Yes, you'll have more power at the cost of smoothness.

@DinosTinkerShed 2 года назад

Have not ridden it yet. Still 2 feet of snow here. I am aware of the surging issues, this is why I did not cut the top out of the air box, right now I can reverse everything to stock if I have too. My main goal was not more power but to install the adjustable mixture screw to add some fuel at idle. Thank you for the comment and feedback, it is appreciated. Dino

@robertmayer2071 2 года назад

cool shed im considering buying a 2022 dr 650 i live 20 miles to the east of you in newfane ny that big snow on jan 17 was no joke how do you heat your shed wood ?

@DinosTinkerShed 2 года назад

Very nice, my wife is from Niagara Falls New York not too far from you. we still have snow in our yard from the storm, something else Ill tell you. My shop is a bit to small for a wood stove by the time you factor in the clearances. I use a combination of a propane heater and electric. This spring I plan on insulating the shed, did not really plan on it being a studio in the winter but it has become just that. Thank you for the comment and no matter what you buy, DR650 or other bike, you will have lots of fun for sure. Dino

@robertmayer2071 2 года назад

@@DinosTinkerShed just put a down payment on a 22 dr 650

@DinosTinkerShed 2 года назад

Thanks great news, congratulation! Dino

@robertmayer2071 2 года назад

@@DinosTinkerShed brought her home this morning had to work today havent even rode her yet. question do you ever cross the rainbow bridge in the falls ? you look familiar i work in the toll booths at rainbow.

@DinosTinkerShed 2 года назад

@@robertmayer2071 LOL I have not crossed the Rainbow in a few years, I use the lower bridge when I cross, only been across once in the last two years though. Hopefully this year will be better, Karl and I want to ride some of your great country!

@erich1880 2 года назад

That thumb nail! Ouch! What video did that happen on? 😮 Lol

@DinosTinkerShed 2 года назад

Lol that happened off camera. Pretty nasty eh?

@Wolfdog370 2 года назад

Umm .. here's a tip .. if people click on an air box mod they want to kick off on topic .. they are probably not interested in the weather or snow ploughing or views of a coffee cup .. in other words, get to the point from the get go

@DinosTinkerShed 2 года назад

Hey thank you for the tip. I know my intros can be kind of long, that's why I take the time to include time code chapters that allow those who do not want to take the time to watch the opening to skip through. Thanks again for taking the time to comment, I actually have slimmed down the opener and intros a bit over the year recognising this. Dino

@stevemain3444 2 года назад

@@DinosTinkerShed Hi Dino, don't change a thing mate! Am enjoying the scenery, buildings etc from a place I'll possibly never get to visit and I'm picking up some great tips and tricks for my DR too (loved the cheap GS screen mod btw). Wishing you good adventures from New Zealand.